Process of making cylinders for internal-combustion engines



E. E. ALLYNE.

PROCESS 0E MAKING CYLINDERS FOR INTERNAL COMBUSTION ENGINES.

APPLICATION FILED MAH. Z9. I9I5.

2 SHEETSMSHEET I.

E. E. ALLYNE.

PROCESS 0F M NNNNNNNNNNNNNNNNNNNNNNNN L c NNNNNNNNNNNNNNN s.

APPLICATION FILED MAR.29, I9l5. 1,347,476. mentaal July 20,192@

2 EEEEEEEEEEEE 2.

EDMUND E. ALLYNE` OF CLEVELAND,

CASTINGS COMPANY, or CLEVELAN OHIO, ASSIGNOR TO THE ALUMINUM D, OHIO, A 'CORPORATION 0F OHIO.

PROCESS OF MAKING CYLINDERS FOR INTERNAL-COMBUSTION ENGINES.

Specification of Letters Patent.

Application led March 29, 1'915. Serial No. 17,657.

To all wlw/1t t may concern:

Be it known that I, EDMUND E. ALLYNE, a citizen of the United States, residing at Cleveland, in the county of Cuyahoga and State of Ohio, have invented certain new and useful Improvements in and Relating to Processes of Making Cylinders for In ternal-Combustion Engines, of which the following is a specification.

This invention relates to a process of making motor cylinders, more particularly cylinders for use in internal combustion motors of the reciprocating piston type.

One object of the invention is to provide such a motor cylinder of relatively light -weight without sacrificing either strength or durability.

Another object of the invention is to provide such a motor cylinder with improved heat dissipating characteristics and also one in whichthere will be substantially uniform expansion of the cylinder walls to be traversed by the piston, thereby reducing to a minimum frictional resistance between the cylinder and piston.

Another object of the invention is to provide such a cylinder having a wall of iron, or material of equal resistance to wear, which shall be of substantially uniform cross-sectional area throughout its length traversed by the piston and supported properly by a metal of considerably less specific gravity, .so as to insure on the one hand substantially uniform expansion of the cylinreducing to a minimum mechanical friction losses between the cylinder and the piston, and on the other hand to reduce to a minimum the weight of the cylinder as an entirety, without sacrificing necessary strength and durability. I prefer that the metal of the supporting struct-ure shall be a better conductor of heat than the metal of the cylinder walls With which the piston engages, and also that ,it shall have a higher co-efcient `of expansion.

Another object of the invention is to provide such a cylinder from which relatively. high thermal and mechanical efficiencies mayv be obtained and'with which troubles incident to over heating and unequal heat eX- pansion of the cylinder walls are practically eliminated.

Another object of the invention is to provide such a `ylinder with iron walls of unider wall, thereby With these and other objects in view, the invention consists of steps hereinafter described in connection with one way of carrying out my invention, selected for the purpose of illustration.

First I cast from aluminum or an aluminum alloy, or other metal of similar character a cylinder section or a plurality'of cylinder sections en bloc, preferably with the desired water j acket formed around each such section in the casting. This may be done in any well known manner, the idea being to make the resulting structure as light as is consistent with necessary strength and durability. The inner wall of each cylinder section, that is, the wall at the inside of the water jacket, may be comparatively thin since when the cylinder is completed there is no rubbing or sliding motion of any sort against this wall which will occasion wear and tear thereof. Furthermore the thinner the wall the better its capacity as a heat conductor and the more quickly will it transfer heat from the cylinder proper to the cooling liquid in the water jacket.

In actual practice I have found the best results are obtainable by making thiscasting of an aluminum copper alloy, it being understood that the proportion of copper used ldepends upon the degree of hardness desired.

be of Substantially uniform cross-sectionalv area throughout'its length which is engaged by the piston, both interior and exterior Patented July 20, 1920.

`ished cylinder.

walls ofthe liner may be prepared or surfaced in any suitable manner as by turning, boring, grinding or accurate drawing. The exterior diameter of the liner should be such that when the liner is pressed into the finished aluminum cylinder section the interior walls of the aluminum cylinder and the exterior walls of the liner will be in snug engagement or intimate contact with each other. circ'umferentially and particularly throughout the length of piston travel within the iron cylinder section. As the walls of the liner which are subjected to strains and stresses are to be suitably supported at all points, they may be relatively thin, so as to make a comparatively light liner.

I then press the iron or steel liner into the aluminum cylinder section. This step may be performed in any suitable manner. have found it more advantageous to insert the liner from the upper open end of the cylinder section and toforce it into place therewithin under requisite pressure.

Lastly I preferably secure the liner in position from either one or both ends thereof in any suitable manner, so that itv cannot move to and fr0 relative to the aluminum cylinder section during the operation of the piston within the iron liner. Preferably I provide the iron liner at its upper end with a boss or flange which I seat in a corresponding recess inthe surrounding aluminum cylinder section. This boss or {iange may be engaged and held in place against axial movement outwardly by the necessary cylinder head to complete the motor cylinder, as an entirety, which head may be suitably shaped for the purpose and removably secured in position on the aluminum casting in any well known manner.

There it is desired to mak cylinders lembodying my iniention applicable to the puppet valve type of hydro-car bon motor, I prefer to provide the necessary valve seats of iron or steel and to cast them into the aluminum cylinder casting when it is formed. In this connection I previously prepare a piece or pieces of iron or steel of suitable length. breadth and thickness to provide the necessary valve seats in the fin- These valve seat inserts I properly locate and suitably support in the mold. so that when num alloy is cast about them they will be properly positioned and securely held in the resulting cylinder casting. it advantageous in the final preparation of the cylinderto previously perforate .these iron or steel valve seat pieces at the place oi places where a valveseat is to be ultimately formed therein so as to assist in the machining thereof after the casting is completed. I have also found it advisablev` in order to insure the locating of these valve Seat pieces fixedly Within the casting. to

a cylinder or proper to the water in the water jacket.

the aluminum or alumi-.

I have found scarf, bevel or notch the edges thereof so as to provide increased surfaces for engagement of iron or steel and aluminum or alloy and to have this engagement effective in various planes. It may not be necessary in each instance to provide such inserts for the inlet valve seats, though undoubtedly it will be found advantageous always to employ them for the exhaust valve seats. In the latter connection, tungsten steel may be used to great advantage, .as a valve seat formed in it will not pit under ordinary-circumstances or accumulate carbon incrustations.

@Wing to the high heat due to the burning of gases of combustion within motor cylinders of this type, provision must be made for the expansion and contraction of the piston and the cylinder walls with which it engages. If the cylinder walls with which the piston engages are substantially homogeneous in texture and material and are of substantially uniform cross-sectional area at all positions of piston travel, the effect of heat will be substantially uniform at all points of the cylinder and mechanica/ly frictional losses reducedto a minimum. In iron castings in which the cylinder Walls and water jackets are formed integrally, it has been practically impossible to insure that the cylinder walls will be of uniform thickness or uniform cross-sectional area over the length .of the cylinder traversed by the piston, and where varying thicknesses of crosssectional area ofthe cylinder walls are met with. different degrees of expansion or contraction under the influence of heat will be found to exist, resulting in lack of concentricity or in the existence of eccentricity of the cylinder walls, with"consequent frictional binding upon the piston during its travel. Furthermore the c'o-eflicient of heat conductivity of iron it is not a highly eflicient conductor of heat is not relatively high so that of the-gases of combustion which have to be conducted from the interior of the cylinder bly idea has been to make the inner cylinder wall, which is immediately traversed by the 'piston. of substantially homogeneous texture and material and of substantially uniform cross-sectional area so as to insure substantially uniform action of all portions or parts thereof under the influence of the heat within the motor cylinder and to avoid the possibility of blow-holes or unhomogeneous sections of iron or metal throughout the length of the piston'travel. It iswith this object in view that I provide the tubular liner or inner cylinder of iron or steel which may be drawn to accurate internal 'and cxternal diameters or may be machined in any suitable manner to accurate internal and eX- ternal diameters, so as to insure practical uniformity of cross-sectional area and structure of material throughout the length of said liner to be traversed by the piston. This cylinder of uniform support in position by the cylinder section or outer cylinder of cast metal which latter has considerably higher co-efiicients both of heat conductivity and expansion than the iron of the inner cylinder or liner so as to materially assist in conducting heat to be transferred from the inner cylinder to the cooling circulating fluids, and to do this with greater rapidity and efficiency than is now possible with cast iron. For this purpose I have found aluminum or an aluminum alloy to be peculiarly advantageous because in addition to possessing higher co-efficients both of heat conductivity and expansion, it has a much lower specific gravity than iron, whereby the resulting structure as an entirety is considerably lighter than when made entirely of iron, a saving in weight of approximately twenty (20) per cent. being in this way made possible without sacrificing necessary strength and durability. The aluminum or aluminum alloy may be readily cast so as to produce the desired 4number of cylinders with properly located water jackets'and cheaply surfaced to receive and properly support the iron liner or liners. And in thus machining the inner surfaces of the cylinder casting there is opportunity to spect said surfaces for porosity and, if necessary, a casting defective in this respect can be discarded. YWith porosity thus avoided, continuous contact is insured of the inner surface of the cylinder casting and the outer surface of the liner.

A motor constructed with cylinders embodying my invention and completed in accordancewith my process has proven most efficient both thermally and mechanically. ndesirable frictionalv resistance to piston travel between the piston and cylinder walls which it immediately traverses has beenv` greatly minimized. The motor as an entirety is kept relatively cool in operation, the Vheat due to combustion of the motive fluid or gases which is transferred through the cylinder walls being efficiently conducted to the cooling agent, largely because of the comparative thinness of the iron liners and the relative efficiency of the aluminum supporting it in the conducting of the heat to the water or cooling agent. I

It has been found that in order to produce more efficient and economical motor vehicles using hydrocarbon motors as prime movers. all unnecessary weight should be eliminated. Such a motor vehicle motor provided with cylinders made according to my improved process Weighs about twenty (20) per cent. less than the same motor when ymade entirely of cast iron, more than seventy pounds in the example in question, the motors being four Cylinder, four cycle con:

cross-sectional area I struction. The reduction of this amount of -weight naturally is of the utmost value in itself. notwithstanding the additional advantages in thermal and mechanical efficiencies incident to the motor with cylinders made under my improved process.

The iron liners are inserted after the aluminum casting, which supports them, has been made and preferably at normal atmospheric temperature so that there is no possibility of them being Warped, distorted or gotten out of shape by being subjectedto high temperatures, such for example as those to which it would be necessary to subject them were molten aluminum or alloy molded about the liners to form eX- terior cylinder walls and water ackets. After the liners have been inserted there is no need of re-surfaci'ng their inner walls with which the pistons engage because of any conditions to which such walls are sub- 'jected in getting the liners into the tubular aluminum sections.

In' multiple cylinder motors each cylinder prepared/in accordance with my process is substantially exactly the same as each other cylinder so asto insure practically the same condition of cylinder walls in all of the cylinders, a great advantage in producing smooth running, evenly balanced and highly efficient motors.

for any reason it should be desired to renew or replace a liner, it will be understoot that the same may be accomplished readily merely by pressing it out of its tubular aluminum support.

As the co-efficient of expansion of aluminum is greater than that or iron, there is no danger that the aluminumsection surrounding each.iron line-r and valve seat insert will not expand sufficiently to maintain the proper relations of these correlated parts, despite the fact that the iron or steel. is subjected to higher temperatures than the aluminum or aluminum alloy.

As each iron liner may be made relatively thin, it will be comparatively light in weight and accordingly may be made, without prohibitive expense, of a much higher grade of material than cast iron cylinders, at the same time insuring that the cylinder Walls' which immediately confine the gases of combustion and are engaged by the piston will be of substantially homogeneous metal throughout their length traversed by the piston.

Having described one Way of carrying out my process, I will now describe a specific construction of a. motor cylinder, step by step, made in accordance with my invention.

In the drawings, Figure l is a view of a motor cylinder casting, partly in section, made in accordance with the rst step of my process.

Fig, 2 is a perspective View of a, liner many made in accordance with one ofthe steps ofl my process.

Fig. 3 illustrates the step'inmy process of inserting the liner into a tubular section of the cylinder casting.

Fig. 4 is a vertical section, through a tubular section, a head being shown upon the casting and engaging with the upper Walls of the liner to hold the latter against outward movement.

Figs. 5 and 6 are fragmentary views illustrating the method of positioning and holding a valve seat insert.

The first step is to make the casting 2.

The one shown in the drawings-is an en bloc` cylindery casting ,for a four-cylinder, fourcycle type of motor. It is made of an. aluminum-copper alloy. The casting 2 has as tubular sections 2b as the motor is to have cylinders. These tubular sections 2, suitable water jackes 2', and gas intakes 3 and exhaust outlets 4 arev formed integral, the casting being made in a suitable mold in a well known manner.

After the casting 2 is completed and ready for handling, each tubular section 2b thereof may have its inner wall suitably surfaced if necessary in order to have such walls concentric with the axis of the cylinder as an entirety of which it forms the outer wall section. This surfacing may be done in any suitable manner as by turning, boring or grinding. Care should be taken that said inner walls are free from porosity.

In the finishing of the tubular section 2b I arrange a recess 2c at the upper end thereof for a purpose to be hereinafter set forth.

Next I prepare a tubular liner 5 of iron or metal possessing greater resistance to frictional wear and tear than aluminum o1 aluininum-copper alloy and also a I metal which has lower co-eflicients both of expansion and heat conductivity." This liner may be constructed in any suitable manner as by drawing, turning, boring or grinding, so that its inner and outer walls will be concentric to the axis of the liner and the crosssectional area of the liner will be the same throughout the length thereof to be traversed by a piston. Furthermore, I make this -liner relatively thin and of substantially homogeneous texture throughout for the purposes hereinbefore stated. In the making of the liner I have found it advantageous to form aJlange 5a at the upper end thereof 'for a purpose to be hereinafter set forth.

- Next I introduce the lower end of a liner into the upper end of a tubular section 2b and then press or force the liner down into.

the tubular section 2b until the flange 5a on the liner seats itself in the recess' 2c in the upper end of the tubular section 2", it being understood that .the diameter of the internal walls of the tubular section 2b and the external Walls, of the 111161 5.- ?Ie .such as to cause an intimate engagement of these walls when the liner is pressed into the tubular v section which supports it.

l Next the liner is secured against longitudinal movement. For this purpose I have shown a cylinder head 2a which engages with the upper wall of the flange 5a of the liner. This head may be secured to the casting 2 in any suitable'and well known manner (not shown) and when so secured holds the liner against longitudinal movement outwardly, the engagement of the under wall of the flange 5a with the adjacent wall of the recess 2c serving to prevent the longitudinal movement of the liner inwardly.

For the purpose of illustration I have shown the motor in the drawings to be of the puppet valve type.

7 isa metal insert preferably of iron or steel which is embedded ,in the casting 2 when the latter is made. That is, in connection with the first step of my process, a metal insert is placed in and suitably supported in the mold for the casting 2 and when the casting is made the insert is at the same time embedded therein. As shown in the drawings these inserts 7 have openings 7', 7a, which aline with the inlet and outlet openings, respectively, cylinder. Each insert 7 may have its edges beveled as shown at 7 b and its opposite sides cut away as shown at 7 c, to provide effective means for securing and holding it within the casting.

It will be understood that in referring either to aluminum or aluminum alloy I have in mind either or both of them.

To those skilled in the art many modifications of and widely differing embodiments and applications of my invention within the bounds of thefollowing claims will suggest themselves. My disclosures and the description herein are purely illustrative and are not intended to be in any sense limiting.

What I claim is:

for the gases for each 1 The herein described process which".

consists in casting from a metal having a higher co-efiicient of heat conductivity and a softer consistency than iron, a tubular .section surrounded by cooling means, forming a tubular liner of iron the walls of which at .any cross sectionA are of uniform thickness throughout and then inserting said liner into said tubular section of said casting and causing intimate contact between its exterior relatively hard surface and the relatively soft interior surface of said casting wherever heat is to be transferred through said liner and casting to said cool- `ing means.

2. The herein described process which consists in casting from a metal having a higher co-eiiicient of expansion and a softer consistency than iron, `a tubular section Surrounded by Sealing .means forming a cooling means,

throughout, and then inserting said liner into said tubular section of said casting and surface of said casting wherever heat is to be transferred through said liner and casting to said cool-v ing means.

3. The herein describedv process which consists in casting from a metal having higher co-eiiicients both of heat conductiv` expansion and a softer consistency, t an iron, a tubular section surrounded by forming a tubular liner of iron the walls of which at any cross section are of uniform thickness throughout, and then inserting said liner into said' tubular said cooling means. y

4. The yherein described process which consists in casting from, a metal having a lower specific gravity and higher co-eiicients both of heat conductivity and eX- pansion and a softer'consistency than iron, a tubular section surrounded by cooling means, forming a tubular liner of iron the walls of which at any cross section are of uniform thickness throughout, and then'ininto said tubular section 5. The herein Adescribed process which consists in making a casting of aluminum alloy having a tubular section surrounded y cool' surfacing the inner wall Aand casting to said cooling by cooling means, forming a tubular linerof iron the Walls of which at any cross section are ofuniform thickness throughout, and surfaced externally and internally, and then inserting said iron liner vinto said tubular section of said casting and causing intimate contact between its exteriork relaand the relatively soft interior surface of said casting wherever heat is to be transferred through said liner and casting to said coolingmeans.

7. The hereindescribed process of making cylinders for internal combustion motors which consists in casting from a metal having higher coefiicients both of heat conductivity and expansion and a softer consistency than iron, a tubular section surrounded by cooling means with iron valve seats, embedded therein," formin a tubular liner of iron the walls of whlch at any cross section are of uniform thickness throughout, and then inserting said iron liner into said tubular section of said casting and causing intimate contact between its exterior surface and `the interior surface of said casting wherever heat is to be transferred through said liner and casting to said cooling means, the correlation between said iron liner being maintained solely through the metal of said casting which has higher coeicients both of heat conductivity and expansion than iron.

In testimony whereof I affix my signature, in the presence of two witnesses.

EDMUND E, ALLYNE. v Witnesses:

M. B. KING, 4EDWARD R. ALEXANDER.

valve seat and said. iron Correction in Letters Patent No. 1,347,476Q

It is hereby certifiedy that in Letters Patent No. vl ,347 ,47 6, granted JulT 20, 1920,

l upon the application of Edrnund EQAllyne, of Cleveland, Ohio, for an improvement in @Processes of Making Cylinders for InternaleCombustion Engines, an error appears in the printed specification requiring correction as followsz' Page 5,i line 45, claim 5, before the Word surfacingf'nsert theword cylindrically; and

that' theV said Letters Patent should be read with :this correction therein that the same may vconforrn to the'record of the case in the Patent Gfice.

Signed and sealed this 24th day of August, A. 1920.

' `M. H. ooULsToN,

Acting Commissioner of Patents.'

[SEAL] 

